Tohatsu MFS 8 S [35/84] General notes on service

Содержание

• Top page 1
• Chapter 1 specifications 2
• Chapter 2 service data and tools 2
• Chapter 3 inspection and maintenance 2
• Chapter 4 power unit 2
• Contents 2
• Chapter 5 lower unit 3
• Chapter 6 recoil starter 3
• Chapter 7 carburetor and fuel pump 3
• Chapter 8 oil pump 3
• Chapter 9 electrical system 3
• Chapter 9 test run and inspection 3
• Contents 3
• Chapter 1 specifications 4
• Dimensions 4
• Engine 4
• Item model or 4
• Performance 4
• Specifications 4
• Type 8a 9 a 4
• Chapter 1 specifications 5
• Item model or 5
• Lower unit 5
• Specifications 5
• Type 8a 9 a 5
• Warning systems 5
• Chapter 1 specifications 6
• Dimensions 6
• Chapter 2 service data and tools 7
• Service data and maintenance standards 7
• Chapter 2 service data and tools 8
• Chapter 2 service data and tools 9
• Chapter 2 service data and tools 10
• Chapter 2 service data and tools 11
• Chapter 2 service data and tools 12
• Chapter 2 service data and tools 13
• Chapter 2 service data and tools 14
• Chapter 2 service data and tools 15
• Table of points to apply sealants adhesives and lubricants 15
• Chapter 2 service data and tools 16
• Chapter 2 service data and tools 17
• Chapter 2 service data and tools 18
• Description bolt or nut thread 18
• Engine 18
• Lower unit 18
• N m kg m lb ft 18
• Standard torque 18
• Table of tightening torque 18
• Tightening torque 18
• 1 general tools 19
• Chapter 2 service data and tools 19
• Disassembly and repair 19
• Tools and instruments required for 19
• Tools and instruments required for disassembly and repair 19
• Chapter 2 service data and tools 20
• Chapter 2 service data and tools 21
• How to use special tools 21
• Chapter 2 service data and tools 22
• Chapter 2 service data and tools 23
• Drive shaft bearing tool 3b2 72256 0 23
• Backlash measuring tool 24
• Chapter 2 service data and tools 24
• Chapter 3 inspection and maintenance 25
• O o o o 25
• Periodical inspections 25
• Troubleshooting 26
• Change of engine oil 27
• Chapter 3 inspection and maintenance 27
• Method to change engine oil 27
• Chapter 3 inspection and maintenance 28
• Inspection of fuel system 28
• A caution 29
• Chapter 3 inspection and maintenance 29
• Compression test 29
• Chapter 3 inspection and maintenance 30
• Chapter 3 inspection and maintenance 31
• Inspection of timing belt 31
• Change of gear oil 32
• Chapter 3 inspection and maintenance 32
• A caution 33
• Chapter 3 inspection and maintenance 33
• Flushing cleaning 33
• Chapter 3 inspection and maintenance 34
• Inspection of cooling system 34
• Chapter 4 power unit 35
• General notes on service 35
• Chapter 4 power unit 36
• Removing parts 36
• Removing power unit 36
• Removing power unit removing parts 36
• Chapter 4 power unit 37
• Chapter 4 power unit 38
• Disassembling engine 38
• Chapter 4 power unit 39
• Chapter 4 power unit 40
• Chapter 4 power unit 41
• Chapter 4 power unit 42
• Engine parts 42
• Inspection and measurement of 42
• Inspection and measurement of engine parts 42
• Chapter 4 power unit 43
• Chapter 4 power unit 44
• Chapter 4 power unit 45
• Chapter 4 power unit 46
• Chapter 4 power unit 47
• Chapter 4 power unit 48
• Chapter 4 power unit 49
• Chapter 4 power unit 50
• Repair and replacement of engine 50
• Repair and replacement of engine parts 50
• Chapter 4 power unit 51
• Reassembling engine 51
• Chapter 4 power unit 52
• Chapter 4 power unit 53
• Chapter 4 power unit 54
• Chapter 4 power unit 55
• Chapter 4 power unit 57
• Chapter 4 power unit 58
• Chapter 4 power unit 59
• Chapter 4 power unit 60
• Chapter 5 lower unit 61
• Disassembly of gear case 61
• Chapters lower unit 63
• Disassembly of propeller shaft and clutch 63
• Disassembly of water pump case 63
• Chapter 5 lower unit 64
• Removal of cam rod drive shaft and bevel gear 64
• Chapters lower unit 65
• Chapters lower unit 66
• Gear case assembly 66
• Installation of bevel gear and driveshaft 66
• Installation of clutch cam and cam rod 66
• Assembly of water pump case 67
• Chapters lower unit 67
• Assembly of propeller shaft and clutch 68
• Chapters lower unit 68
• Chapter 5 lower unit 69
• Installation of gear case 69
• Standards for oil seals and o rings for gear case 69
• Chapter 6 recoil starter 71
• Chapters recoil starter 71
• Recoil starter starter lock 71
• Chapters recoil starter 72
• Disassembling 72
• Reassembling 72
• Chapters recoil starter 73
• Inspection 73
• A caution 74
• Carburetor 74
• Chapter 7 carburetor and fuel pump 74
• A caution 75
• Chapter 7 carburetor and fuel pump 75
• Fuel pump 75
• Chapter 8 oil pump 76
• Component parts 76
• Br w brown with white tracer 77
• Chapter 9 electrical system 77
• Ef type 77
• Lg b r r w w r 77
• Lg____lg 77
• Mf type 77
• Note including optional parts in the diagram 77
• Or orange 77
• Rec reg 77
• Red with white tracer white with red tracer 77
• Tracer 77
• W r v r 77
• W r w r 77
• White yellow light green black with red 77
• White yellow light green black with red tracer red with white tracer white with red tracer 77
• Wire caldr 77
• Wiring diagram 77
• В black l blue bt brown g green grange 77
• В black lue rown reen 77
• Chapter 9 electrical system 78
• Ep type 78
• Inspection 78
• After the tester pointer shakes once 79
• Before measuring the item marked with con make a shortcircuit between the ignition terminal and earth terminal 79
• Chapter 9 electrical system 79
• Condition of the above measurement hioki 3030 tester was used with the measurement range of 1 kq 79
• Oo marked with con indicates a minute value because the tester pointer shakes a little for this item 79
• Since the value marked with con is the capacitor characteristic the tester reads a stable value shown in parentheses 79
• Tester s negative terminals 79
• Tester s positive terminals 79
• The values shown in the above table are just standards and it is impossible to check each value accurately 79
• Tolerance of resistance 20 79
• Chapter 9 electrical system 80
• Chapter 9 electrical system 81
• Ep type cable harness wiring diagram 81
• Ф c d unit 2 rectifier fuse cord chock solenoid starter solenoid stop switch 81
• Chapter 10 test run and inspection 82
• Inspection 82
• Test tank and test propeller 82
• Additional tightening after test run 83
• Break in 83
• Break in period 10 hours 83
• Chapter 10 test run and inspection 83
• Check the tightening condition of respective bolts and nuts after test run and additionally tighten them with the 83
• Cooling water and or oil leak from parts joined spots of the engine 83
• Cooling water discharge condition cooling water must vigorously be discharged from the water inspection 83
• Engine speed at acceleration and deceleration 83
• Extraordinary noise 83
• Fuel leak from parts joined spots of the engine 83
• Idle speed and stable idling 83
• Inlet exhaust valve etc is replaced perform a break in of the engine for fitting the sliding surfaces 83
• Items to be checked during test run 83
• Note perform a break in of the engine according to the following standards 83
• Off the lamp goes out as the engine starts 83
• On off operation of the engine oil warning lamp 83
• On the lamp goes on when the lead wire of the oil pressure switch is grounded to the body 83
• Operation of the clutch 83
• Operation of the stop switch 83
• Specified tightening torque 83
• When any of the piston piston ring piston pin crank shaft connecting rod cylinder cam shaft rocker arm 83
• While idling the engine check the following items 83
• Back cover 84
• Tomatsu corporation 84

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CHAPTER 4 POWER UNIT 1 General Notes on Service When servicing the engine pay attention to the following instructions that are mandatory and general notes on servicing the outboard motor in whole Work carefully during maintenance and repair to avoid injuries and accidents 1 When servicing the outboard motor be sure to securely fix it on a proper workstand For servicing the power head it is convenient to use the setting board 2 Be careful not to scratch or damage the mating surfaces of the cylinder cylinder head drive shaft housing and coated surfaces etc during servicing 3 Don t reuse packings gaskets O rings split pins that are once removed for servicing Replace them with new ones when reassembling Deformed snap rings must be also replaced 4 Be sure to use genuine parts Always use genuine or specified oil and grease 5 For services that require to use a special tool s use the specified tool s following the instructions 6 On disassembling and removing parts pay careful attention to mating point marks of respective parts If no marks on it make simple marks at those mating points for convenience for reassembling 7 To avoid losing small parts temporarily restore bolts nuts washers and other small parts to their respective original positions as far as circumstances permit 8 When parts are removed for disassembling dust them off and wash them with solvent and then check to see if they are worn or damaged 9 While reassembling pay attention to every detail such as mating preciseness in centering air tightness lubrication grease up cleanliness of oil and fuel paths packing wiring piping etc 1 When fastening a part for which many bolts and nuts are used cylinder head crank case etc carefully tighten the bolts and nuts in order from inner ones to outer ones diagonally or circularly to avoid uneven tightening When removing bolts and nuts from such a part carefully loosen and remove them in the reverse manner 2 When inserting an oil seal be careful in setting the correct side up nor to scratch the mating surface lip to the shaft Apply grease onto the lips 3 When applying liquid sealant take care of its quantity and thickness If too much sealant is applied the excess may not only stick out and flow into the case but also have a bad influence When using an adhesive carefully follow the instructions 4 If a fastener is hard to loosen and remove because of rust spray penetrating oil to loosen and remove it after five or more minutes 5 For details of service standards tightening torques parts that are specified to aoolv sealant qlue grease etc refer to the service data table 6 Bolts nuts and washers are indicated by the symbols below H820 Hexagon headed bolt Diameter 8 mm Length 20 mm N8 Normal hexagon nut Diameter 8 mm L8 Hexagon lock nut Diameter 8 mm W6 Plain washer Diameter 6 mm SW6 Spring washer Diameter 6 mm Screw 620 Pan headed screw Diameter 6 mm Length 20 mm Thickness 30 or more Unit mm Setting board for power unit 32